Pilot Valve Actuator Piston Design for Wider Setpoint Control
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Solution Overview
Problem
Existing pilot valve actuators face issues with precision and reliability due to diaphragm cracking, limited range of setpoints, and leakage through flexible hoses, which affect the efficiency and reliability of fluid control systems.
Innovation Solution
An actuator design featuring a piston movably mounted in a housing with a control fluid feed to selectively control fluid pressure, acting on the piston against a loading spring, allowing for a wider range of setpoints and improved reliability by eliminating diaphragm-related failures and hose leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a diaphragm and pin arrangement is used to transmit control pressure, then the actuator can control the loading spring compression, but the diaphragm is prone to cracking and leakage, significantly reducing efficiency
Solution Approach 1:
The patent removes the diaphragm component from the actuator design and replaces it with a piston. This extraction eliminates the reliability issue of diaphragm cracking while maintaining the control pressure transmission function through the piston's mechanical movement in response to control pressure.
Solution Approach 2:
The patent replaces the diaphragm-based flexible membrane system with a rigid piston-cylinder mechanical system. The piston responds to control pressure by moving linearly within the cylinder, providing a more reliable mechanical transmission mechanism that eliminates diaphragm-related failures.
2Adaptability or versatility
If an actuator diaphragm with limited travel is used, then the structure is compact, but the range of compression of the loading spring is restricted, limiting the range of setpoints
Solution Approach 1:
The patent employs a piston with increased travel capability compared to the diaphragm. The piston can move through a larger range within the cylinder, dynamically adjusting the loading spring compression over a wider range, thereby expanding the available setpoint range while maintaining a compact overall structure.
3Ease of manufacture
If flexible hoses are used to connect control fluid source to the diaphragm, then the system is easily assembled, but the hoses are a significant source of leakage and loss of pressure
Solution Approach 1:
The patent removes the flexible hose component from the control fluid path and replaces it with integral bore passages within the actuator body. This extraction eliminates the leakage source while maintaining ease of assembly through a unified, leak-free internal flow path design.
4Device complexity
If a pin arrangement is used to transmit force from the actuator diaphragm to the loading spring, then the mechanism is simple, but the limited travel restricts the compression range of the loading spring
Solution Approach 1:
The patent replaces the limited-travel pin arrangement with a piston that can move through a larger range within the cylinder. This dynamic extension of travel capability allows the piston to compress the loading spring over a wider range, expanding the setpoint adjustment capability while maintaining mechanical simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The piston-based actuator provides a more sensitive and reliable control of pilot valve setpoints, enabling a broader range of pressure modulation and reducing fluid leakage, thus enhancing the efficiency and operational lifespan of fluid control systems.
Implementation Method 1
control fluid feed for introducing a fluid into the actuator chamber to selectively control a fluid pressure in the actuator chamber, wherein the piston is arranged to be acted on by the fluid pressure in the actuator chamber
Implementation Method 2
a loading spring between the piston and the actuation member, wherein the loading spring is arranged to bias the piston against the fluid pressure in the actuator chamber
Data Source
AI summary
An actuator for a pilot valve, including a housing, a piston movably mounted in the housing and an actuator chamber defined between the piston and the housing. The actuator includes a control fluid feed for introducing a fluid into the actuator chamber to control fluid pressure, with the fluid pressure acting on the piston. The actuator also includes an actuation member for acting on the pilot valve and a loading spring between the piston and the actuation member. The loading spring is arranged to bias the piston against the fluid pressure in the actuator chamber. The control fluid feed controls the fluid pressure so the fluid pressure acts on the piston against the bias of the loading spring to control the biasing force.